Method of preparing a frozen, battered food product

ABSTRACT

The process starts with the pre-dusting of the food product to be batter-coated, followed by the application to said dusted food of a prepared batter, the composition of which batter comprises a cellulose derivative that coagulates in a hot water bath or in the presence of water vapour. The process continues with the heating of the coagulated, batter-coated food using a traditional, microwave or infrared oven, so that the coagulated batter coating layer does not melt on cooling, and concludes with the cooling and freezing of the above product.  
     The object of the invention is to eliminate pre-frying, which is the most problematic stage of the classic batter coating processes.

OBJECT OF THE INVENTION

[0001] The present invention is a new process to prepare a frozen,batter-coated food product. The fundamental object of the invention isto eliminate the stage of the equivalent conventional production processin which the food product is pre-fried in oil.

[0002] The process of the invention is applicable to all types of foodsthat can be batter-coated, including pieces of fish and other seacreatures, meat products and vegetable products, etc.

BACKGROUND OF THE INVENTION

[0003] The frying of food is a technique which is widely used as amethod of food preparation in Spain. Batter-coated products are themost-consumed food products prepared using this technique.

[0004] The highest quality of batter-coated products is achieved whenthe fried products are soft and moist inside and are covered with acrispy layer or coating on the outside.

[0005] The energy necessary for frying is provided by the hot oil andpart of this is absorbed by the food, which increases the amount ofcalories provided to the consumers.

[0006] A way of reducing the absorption of oil during the frying ofbatter-coated products is to incorporate substances such as proteins orhydrocolloids into the batter paste. A related patent is U.S. Pat. No.4,900,573, which proposes a formulation for batter coating that containsHPMC. This cellulose gives rise to a considerable reduction inoil-absorption by the food without losing the crispy quality desired bythe consumer.

[0007] The use of microwave ovens has now become an alternative methodto cook food, especially due to the lower fat content of the finalproduct. Both in patent WO 0108513 and in WO 9303634 a batter-coatedproduct is developed from a formulation that has cellulosesincorporated. Said product is prepared in the traditional way(pre-frying in oil and freezing) while providing the advantage that forits final preparation it can be heated in a microwave oven withoutlosing the textural characteristics desired by the consumer.

[0008] Once batter-coating formulations that reduce the absorption ofoil in the food product have been developed and alternative methods tocook the final product have been studied, it would be desirable to finda process to replace the process of pre-frying in oil, which is the mostproblematic in the batter-coated product production process.

SUMMARY OF THE INVENTION

[0009] As stated above, the object of the invention is to eliminate theclassic pre-frying in oil stage, with the problems derived therefrom.This is replaced by immersing the batter-coated product in a hot waterbath. The cCoagulation of the batter coating is achieved thanks to theincorporation of celluloses in the formulation thereof. The cellulosesused gel “per se” when immersed in a bath of hot water. An alternativemethod to prepare batter-coated food is thereby provided which, inaddition to reducing the fat content of the final product, avoids thepre-frying stage, which is the most problematic part of the process.

[0010] In wider terms, the process of the invention consists ofdefrosting the substrate, pre-dusting, coating the substrate in batter,dripping off the excess, coagulating the batter coating in a hot waterbath, heating and freezing.

[0011] As has previously been noted, the process is applicable to thebatter coating of squid rings, onion rings, portions of fish, chicken,mushrooms, courgette, etc.

[0012] In all cases, before processing, the substrate can be either keptfrozen, at a temperature of −18° C. or lower, or not.

[0013] Other features of the invention will become evident in the courseof the present description and are set out in the attached claims.

PREFERRED EMBODIMENT OF THE INVENTION

[0014] Irrespective of the process itself, the participation of specificpre-dusting and batter-coating products is required.

[0015] The pre-dusting phase improves the adhesion of the batter coatingto the substrate. The pre-dusting mixture is fundamentally composed ofwheat flour.

[0016] As regards the composition of the powdered batter-coatingmixture, this includes flours, starches, hydrocolloids, salt, leavenersand water. The flours used can be wheat flour, corn flour or mixtures ofboth. Preferably, the formulation of the powdered batter coating mixturecan contain between 40 and 95% by weight of wheat flour. The wheat flourcan be of just one type or a mixture of different types. The formulationof the powdered batter coating mixture can contain between 2 and 40% byweight of corn flour.

[0017] The starches could be wheat, corn or rice starches. Preferably,the proportion of starch present in the formulation of the battercoating can vary from 0.1 to 30% by weight.

[0018] The hydrocolloids present in the powdered batter mixture arethose responsible for the coagulation thereof in a water bath, thusavoiding the stage of pre-frying in oil that is necessary to coagulatethe batter coating in a conventional production process forbatter-coated products. The composition of the powdered batter mixtureused in the invention incorporates cellulose derivatives that gel in hotwater. Preferably, it uses those cellulose derivatives which, at aconcentration of 2% in water and a temperature between 15-25° C., givean apparent viscosity between 100 and 4000 cP (according to referencemethods ASTM D1347 and ASTM D2363) and form a firm gel at temperaturesof 55-90° C. More preferably, it uses those cellulose derivatives which,at a concentration of 2% in water and a temperature of between 14-25°C., give an apparent viscosity between 1100 and 2100 cP (according toreference methods ASTM D1347 and ASTM D2363) and form a firm gel attemperatures of 55-90° C.

[0019] The formulation of the powdered batter mixture may containbetween 1 and 5% by weight of cellulose derivatives.

[0020] The salt is incorporated in the formulation to provide flavourand may be present in concentrations that vary between 1 and 10% byweight of the powdered batter mixture.

[0021] Bicarbonates and phosphates are the preferred leavening agents.Preferably, mixtures of bicarbonates and pyrophosphates which addedtogether constitute between 2.5 and 6% by weight of the powdered batterare those that provide the desired sponginess to the final product.

[0022] For the preparation of the batter, the water must be at between 6and 15° C. The prepared batter must be kept at 6-15° C. throughout thebatter-coating process.

[0023] The viscosity of the prepared batter affects the texture, colour,aroma, batter adhesion to the substrate, oil absorption in the finalfrying performed by the consumer and crispiness of the final product.The solids content of the prepared batter paste is preferably 35-40% byweight. The appropriate apparent viscosity of the reconstituted batterpaste can vary between 20,000 and 60,000 cP (Brookfield geometry, 2 rpm,spindle No.4), measured in a temperature range of 15-20° C.

[0024] Using these batter coating ingredients, the food to bebatter-coated is pre-dusted, coated in the prepared batter paste andleft to drip for a period of time that may vary between 5 and 10seconds. Once the excess batter has dripped off, the batter-coated foodproduct is immersed in a water bath at a temperature that may varybetween 60 and 90° C. for a time of 10 to 45 seconds.

[0025] The cellulose derivative added to the formulation acts onimmersing the batter-coated food product in the hot water bath,producing the coagulation of the batter coating. The gel formedaccording to this process is thermo-reversible—it melts on cooling—andthe coagulated batter-coated food product is, therefore, subjected toheating.

[0026] The heating can be performed in a conventional, microwave orinfrared oven. Preferably, in a conventional oven the coagulatedbatter-coated product will be heated for 1.5 to 5 minutes at atemperature between 200 and 280° C. Preferably, in a microwave oven thecoagulated batter-coated product will be heated for 10 to 30 seconds ata power that may vary between 400 and 800 W. Preferably, in an infraredoven the coagulated batter-coated product will be heated for 3 to 8minutes in a temperature range of 200-250° C.

[0027] After heating, the product thus produced is cooled, packaged andfrozen for storing at temperatures of −18° C. or lower.

[0028] The final product produced by following the process of thisinvention has the same texture, taste and colour properties as a productproduced by following the traditional process of pre-frying in oil, withthe advantage that fats from the pre-frying stage are not incorporatedinto its composition. Another additional advantage of the process ofthis invention, perhaps one of the most important advantages at anindustrial level, is the elimination of industrial fryers, thus savingenergy, reducing the costs relating to oil, quality control andmaintenance and elimination of the wastes, as well as avoiding thedangers entailed by working at such high temperatures and in thepresence of gases originated by the overheating of oil.

EXAMPLE

[0029] Frozen batter-coated squid rings were prepared in accordance withthe method of the invention, using the following stages:

[0030] The squid rings were pre-dusted.

[0031] They were then coated in the reconstituted batter which containsthe ingredients set out in table 1.

[0032] Subsequently, the coated product was coagulated in a water bath,followed by a heating stage.

[0033] Finally, it was frozen. TABLE 1 Table of components: Wheat flour79.3% Wheat starch 10% Methylcellulose  1.5% Salt  5.5% Sodium glutamate 0.6% Sodium bicarbonate  1.32% Sodium pyrophosphate  1.78%

[0034] The product is manufactured in the following manner:

[0035] The squid rings are defrosted.

[0036] They are blanched by immersing them in boiling water.

[0037] They are pre-dusted.

[0038] The batter is prepared by beating the dry ingredients in table 1with water at 10° C. in the proportion of 1:1.2 by weight.

[0039] The squid rings are coated in the batter, which is prepared andkept at 10-15° C., and are left to drip for between 5 and 10 seconds.

[0040] The rings are immersed in a hot water bath at 70-80° C. for 20-30seconds.

[0041] The batter-coated squid rings are heated in a microwave oven for20 seconds at 700 W.

[0042] The final product is frozen.

1. Process to prepare a frozen, batter-coated food product, having theobject of eliminating the classic pre-frying stage, which process ischaracterized by comprising: (a) pre-dusting the food product to bebatter-coated (b) applying a prepared batter to the dusted food product;the composition of said batter comprises a cellulose derivative thatcoagulates in a hot water bath or in the presence of water vapour. (c)heating the coagulated, batter-coated food product in a conventional,microwave or infrared oven so that the coagulated batter coating layerdoes not melt on cooling due to thermo-reversibility. (d) cooling andfreezing of the heated product.
 2. Process to prepare a frozen,batter-coated food product, according to claim 1, characterized in thatthe powdered batter mixture contains a cellulose derivative which, at 2%by weight of concentration in water and a temperature between 15 and 25°C., has an apparent viscosity between 100 and 4000 cP and forms a firmgel at a temperature between 55 and 90° C.
 3. Process to prepare afrozen, batter-coated food product, according to claim 1, characterizedin that the powdered batter mixture contains a cellulose derivativewhich, at 2% by weight of concentration in water and a temperaturebetween 15 and 25° C., has an apparent viscosity between 1100 and 2100cP.
 4. Process to prepare a frozen, batter-coated food product,according to claim 1, characterized in that the powdered batter mixturecontains between 1 and 5% by weight of the cellulose derivative. 5.Process to prepare a frozen, batter-coated food product, according toclaim 1, characterized in that the powdered batter mixture containswheat flour.
 6. Process to prepare a frozen, batter-coated food product,according to claim 5, characterized in that the powdered batter mixturecontains a gluten-free wheat flour.
 7. Process to prepare a frozen,batter-coated food product, according to claim 5, characterized in thatthe powdered batter mixture contains a thermally treated wheat flour. 8.Process to prepare a frozen, batter-coated food product, according toclaim 1, characterized in that the powdered batter mixture containsbetween 40% and 95% by weight of flour.
 9. Process to prepare a frozen,batter-coated food product, according to claim 1, characterized in thatthe powdered batter mixture contains between 0.1% and 30% by weight ofstarch.
 10. Process to prepare a frozen, batter-coated food product,according to claim 1, characterized in that the powdered batter mixturecontains a leavening mixture of bicarbonate and phosphates that togetherconstitute between 2.5 and 6% by weight.
 11. Process to prepare afrozen, batter-coated food product, according to claim 10, characterizedin that the phosphates may or may not be a binary mixture of phosphates.12. Process to prepare a frozen, batter-coated food product, accordingto claim 1, characterized in that the powdered batter mixture maycontain salt, flavourings and/or colourings.
 13. Process to prepare afrozen, batter-coated food product, according to claim 1, characterizedin that the powdered batter mixture is reconstituted with running waterso that the total solids range from 35 to 45% by weight.
 14. Process toprepare a frozen, batter-coated food product, according to claim 13,characterized in that the water for the preparation is at a temperaturebetween 6 and 15° C.
 15. Process to prepare a frozen, batter-coated foodproduct, according to claim 1, characterized in that the prepared batteris kept at a temperature between 6 and 15° C. throughout the battercoating process.
 16. Process to prepare a frozen, batter-coated foodproduct, according to claim 1, characterized in that the prepared battermixture has an apparent viscosity between 20,000 and 60,000 cP whenmeasured at between 15 and 20° C.
 17. Process to prepare a frozen,batter-coated food product, according to claim 1, characterized in thatthe prepared batter mixture is immersed in a water bath at a temperaturebetween 60 and 90° C. for a time between 10 and 45 seconds to create acoagulated exterior layer.
 18. Process to prepare a frozen,batter-coated food product, according to claim 1, characterized in thatthe coagulated batter-coated food product is heated in a microwave ovenfor a time between 10 and 30 seconds at a power between 400 and 800watts.
 19. Process to prepare a frozen, batter-coated food product,according to claim 1, characterized in that the coagulated batter-coatedfood product is heated in a conventional oven for a time between 1.5 and5 minutes at a temperature between 200 and 280° C.
 20. Process toprepare a frozen, batter-coated food product, according to claim 1,characterized in that the coagulated batter-coated food product isheated in an infrared oven for a time between 3 and 8 minutes at atemperature between 200 and 250° C.